Filed Under (Ford) by admin on 05-06-2011
Removal of Factory Shifter Start by parking the car on level ground and placing chocks in front and behind one of the car’s rear wheels to prevent the car from rolling. Place the car in neutral with the parking brake disengaged. From inside the car, remove the shifter knob, boot, and trim panel around the shifter. Gently pull up on the outside of the trim, the clips will come undone one by one. Once the panel is unclipped, unscrew the knob, with boot and trim panel attached, from the lever and remove the assembly as one piece. Figure 1 indicates where to begin unclipping the panel. Next remove the trim piece, in front of the parking brake lever and cupholders, by gently pulling up on it to release the clips holding it in place. Then disconnect the three electrical connectors connected to it. Figure 2 indicates the panel to remove and see figure 3 for the connectors to disconnect. Also pull the parking brake lever boot over the lever to gain more access to the center console by gently pinching the base of the boot trim to release the clips. Now remove the two kick panels on the sides of the center console to gain more access to the shifter assembly. Remove the two exposed Phillips head plastic clip screws and clips, then gently pull outward on the rear of the panels to remove the three additional spring clips on each panel. See Figure 4. With the panels removed, unscrew the two Torx head screws securing the center console to the dash assembly. Then slide the front seats forward, as far as they will go, to remove the clips securing the center console in the rear. See Figures 5 and 6. Now, gently, lift up on the center console and slide it back an inch or so. To extract the shifter assembly, remove the four 10mm head nuts on the corners of the shifter base and disconnect the shift cables. The rear studs can be seen in figure 7. The front nuts were exposed after removing the kick panels. To remove the shift cables, use a screwdriver, or similar tool, to gently pop the levers off the ball studs on the shifter levers. See figure 8. Now lift up the shifter assembly and slide it back a bit. Using a screwdriver, or similar tool, GENTLY pry out the shift cables from the shifter base (see figure 9). Now turn the shifter assembly 90 degrees and remove the complete assembly from the car out through the space you made between the center console and dash. Note: The shifter base is made from plastic and will crack or break if not gently pryed on. 1. 2. 3. 4. 5. 6. 7. Installation of the Steeda Tri-Ax Shifter Assembly To install the shifter assembly follow steps 1-7 in reverse. Note: Before you have completely finished assembling the car be sure to check operation of the shifter by rowing the lever through all the gears to ensure function is correct. 8.
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Filed Under (Ford) by admin on 07-05-2011
Selector Lever Cable Vehicles Equipped with a 6R60 Transmission Removal All vehicles 1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to Section 100-02. 3. With the selector lever in PARK, disconnect the selector lever cable from the selector lever. Vehicle equipped with a 6R60 transmission 6. Remove the cable shield by prying on the shield closest to the boot, then sliding the shield away from the boot. 4. Disconnect the selector lever cable from the selector lever housing. 7. Unlock the lock tab and disconnect the selector lever cable end from the transmission manual lever. 5. Pull the cable and grommet through the floorpan. 8. Disconnect the selector lever cable from the bracket and remove the cable. Vehicles equipped with a 5R55S transmission 9. Remove the cable shield by prying on the side of the shield closest to the boot, then sliding the shield away from the boot. 10. Unlock the lock tab and disconnect the selector lever cable end from the transmission manual lever. 11. Disconnect the selector lever cable from the bracket and remove the cable. Installation Vehicles equipped with a 6R60 transmission 1. Install the selector lever cable into the bracket. 2. Connect the selector lever cable end onto the transmission manual lever and lock the lock tab. 3. NOTE: If the shield is loose, install a new shield. Install the cable shield. Vehicles equipped with a 5R55S transmission 4. Install the selector lever cable into the bracket. 5. Connect the selector lever cable end onto the transmission manual lever.
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Filed Under (Ford) by admin on 07-05-2011
Removal NOTE: Removal of the vertical EGR cooler is not required to service the thermostats. 1. Remove the upper cooling fan shroud. For additional information, refer to Cooling Fan Shroud — 6.4L Diesel, Upper in this section. 2. Remove the degas bottle. For additional information, refer to Degas Bottle — 6.4L Diesel in this section. 3. Using a mirror, find the end of the upper radiator hose spring clip. Remove the spring clip, disconnect the upper radiator hose from the thermostat housing and position the upper radiator hose aside. 4. Remove and discard the nut and the vertical EGR cooler lower clamp. 5. Remove the bolt and the vertical EGR cooler lower bracket. 6. NOTE: Vertical EGR cooler removed from art for clarity. Disconnect the wiring from the heater return tube. 7. Remove the 2 bolts and position out the LH heater return tube. • Remove and discard the O-ring seal. 8. NOTE: The 6.4L diesel engine uses 2 thermostats. Remove the 4 bolts, the collar and the thermostat housing. • Lift the bottom of the collar up and rotate toward the engine to remove. 9. NOTICE: If the thermostats are contaminated with engine oil, new thermostats must be installed. Reusing a thermostat that has been exposed to engine oil may result in engine overheating. Remove the thermostats and the gasket from the thermostat housing. • Discard the gasket. Installation 1. Install a new gasket and the thermostats into the thermostat housing. 2. Install the thermostat housing, the collar and the 4 bolts. • Tighten to 13 Nm (115 lb-in). 3. NOTE: Vertical EGR cooler removed from art for clarity. NOTE: Install a new O-ring seal. Install the LH heater return tube and the 2 bolts. • Tighten to 13 Nm (115 lb-in). 4. Connect the wiring to the heater return tube. 5. Position the lower vertical EGR cooler bracket and loosely install the bolt. 6. Install a new vertical EGR cooler lower clamp. Tighten the clamp nut in 3 stages. • Stage 1: Tighten the nut to 10 Nm (89 lb-in). • Stage 2: Loosen the nut 720 degrees (2 complete turns). • Stage 3: Tighten the nut to 8 Nm (71 lb-in). 7. Tighten the lower EGR cooler bracket bolt. • Tighten to 62 Nm (46 lb-ft). 8. Connect the upper radiator hose to the thermostat housing. Install the spring clip. • Verify the spring clip is correctly seated. 9. Install the degas bottle. For additional information, refer to Degas Bottle — 6.4L Diesel in this section. 10. Install the upper cooling fan shroud. For additional information, refer to Cooling Fan Shroud — 6.4L Diesel, Upper in this section.
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Filed Under (Ford) by admin on 07-05-2011
Principles of Operation Differential Electronic Module (DEM) and Active On-Demand Coupling The main role of the active on-demand coupling and the differential electronic module (DEM) is to regulate the all wheel drive (AWD) function by distributing torque between the front and rear axles. The system consists of a coupling that combines mechanical, hydraulic and electronic sections. The coupling unit is attached to the rear axle, between the differential gear and the driveshaft. The mechanical and hydraulic sections are driven by the driveshaft. Active on-demand coupling (AOC) has the following characteristics: Permanent AWD with electronic control of torque transfer front to rear 4X4 control module integrated into the DEM Similar to four wheel drive (4WD) operation No driveline wind-up during slow speed maneuvers or parking The system is not sensitive to size differences between the 4 road tires (when driving with a spare wheel, for example). The system is not sensitive to being towed with one axle raised. Inspection and Verification — Electronic Shift 1. Visually inspect for the following obvious signs of mechanical and electrical damage. Visual Inspection Chart Mechanical Axle shafts and universal joints Driveshaft and universal joints Rear differential Differential electronic module (DEM) Fluid leaks Matching tire size 2. If the concern remains after the inspection, connect the scan tool to the data link connector (DLC) located beneath the instrument panel and select the vehicle to be tested from the scan tool menu. If the scan tool does not communicate with the vehicle: check that the program card is correctly installed. check the connections to the vehicle. check the ignition switch position. 3. If the scan tool still does not communicate with the vehicle, refer to the scan tool manual. 4. Carry out the DATA LINK DIAGNOSTICS test. If the scan tool responds with: CKT914, CKT915 or CKT70 = ALL ECUS NO RESP/NOT EQUIP, refer to Section 418-00. NO RESP/NOT EQUIP for DEM, GO to Pinpoint Test A. SYSTEM PASSED, retrieve and record the continuous diagnostic trouble codes (DTCs), erase the continuous DTCs and carry out the anti-lock brake system (ABS) module self-test. Carry out one key cycle after clearing codes. 5. If the DTCs retrieved are related to the concern, go to the 4X4 Control Module (DEM) Diagnostic Trouble Code (DTC) Index to continue diagnostics. 6. NOTE: Not all DTCs cause the traction control indicator to illuminate. Refer to the table for specific DTCs. When the 4X4 control module (DEM) detects certain types of faults in the AWD system, a DTC is set and the traction control indicator will stay illuminated until the condition has been repaired and the DTCs are cleared using the scan tool. Carry out one key cycle after clearing codes. DTC P0562 System Voltage Low P0563 System Voltage High P0602 Powertrain Control Module (PCM) Programming Error P0606 ECM/PCM Processor Electrical Smart junction box (SJB) mini-fuse 19 (10A) Differential electronic module (DEM) Wiring harness Connector(s) Circuitry Description Traction Control Indicator State OFF OFF ON ON
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Filed Under (Ford) by admin on 06-05-2011
NOTE: Before starting the adjustment process, inspect the top for damage, make sure that the door window glass and rear quarter glass are correctly adjusted then completely lower all window glass. NOTE: After each adjustment make sure the convertible top operates correctly. The Convertible Top Dowel Pins Fall Forward (Overshoot) or Rearward (Undershoot). The Receiver Cups — Cam Bolt Adjustment. 1. Remove the quarter trim panel. For additional information, refer to Section 501-05. 2. Close the convertible top and examine the position of the dowel pins relative to the receiver cups. 3. Move the convertible top to the half-open position to access the cam bolt. 4. NOTE: Rotating the top of the cam bolt toward the front of the vehicle will lengthen the top, increase the tension on the top and increase pull-down effort. Rotating the cam bolt in the opposite direction will have the opposite effect. NOTE: Turn the adjusting cam one notch at a time. Adjust the adjusting cam as needed. 1. Remove the cam stop set screw. 2. Rotate the adjusting cam. 3. Install the cam stop set screw. 5. Make sure the convertible top operate correctly. 6. Install the quarter trim panel. For additional information, refer to Section 501-05. 7. Close the convertible top. Convertible Top Lifts Up Unevenly — Lift Cylinder and C-pivot Inspection 8. Remove the quarter trim panel. For additional information, refer to Section 501-05. 9. NOTE: This step applies to vehicles equipped with the Mach sound system. Remove the screws and disconnect the electrical connectors. 10. Remove the screws. 11. Remove the speakers. For additional information, refer to Section 415-03. 12. Move the convertible top to the half-open position and support the convertible top in that position. 13. Remove the lift cylinder rod mounting bolts. 14. Remove the nuts and support the lift cylinders. 15. Using the convertible top switch, retract the lift cylinder rods and check for bent or binding rods. If one rod bottoms out 25mm (1 inch) or more before the other, the lagging lift cylinder may be bent and will need to be replaced. 16. With the lift cylinder rods retracted, manually lower the convertible top. 17. Manually lift each side rail 7.5-10 cm (3-4 inches) to check for obvious binding. Side arms should have equal resistance, side-to-side. If the resistance is noted, loosen the clamp load of the c-pivot rivet with using a center pinch. If a dramatic resistance is still noted replace the c-pivot rivet with shoulder bolt kit (F5ZZ- 76539A04-A). 18. Position the lift cylinders and install the nuts. 19. Install the two cylinder rod mounting bolts. 20. Install the speakers. For additional information, refer to Section 415-03. 21. Install the screws. NOTE: This step applies to vehicles equipped with the Mach sound system. 22. Install the screws and connect the electrical connectors.